Flexible battery matrix for a conformal wearable battery

ABSTRACT

A matrix of battery cell modules includes a flexible printed circuit board assembly (PCBA) for a conformal wearable battery (CWB) with a plurality of attachment sections for each of a plurality of battery cells that are arranged in a grid-like pattern on a same side of the flexible PCBA. Each battery cell may be joined with a flexible PCB via a welding process. The flexible PCBA is configured to fold along a bend axis so that the flexible PCBA is folded approximately in half. When affixed to the flexible PCBA, the plurality of battery cell modules and a circuitry module form a grid of physical components. When folded, the flexible PCBA forms a three-dimensional grid of physical components comprising at least the battery cell modules.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority as both a continuationof U.S. application Ser. No. 17/085,864, filed on Oct. 30, 2020, nowU.S. Pat. No. 10,980,116, which is a continuation-in-part of U.S. patentapplication Ser. No. 17/038,287 filed on Sep. 30, 2020, now U.S. Pat.No. 11,064,604; and as a continuation-in-part of U.S. patent applicationSer. No. 17/038,287 filed on Sep. 30, 2020, now U.S. Pat. No.11,064,604, all of which are incorporated by reference in theirentireties. This application is related to U.S. application Ser. No.17/085,873 filed on Oct. 30, 2020, entitled “Housing for a ConformalWearable Battery,” now U.S. Pat. No. 11,081,755, U.S. application Ser.No. 17/085,991 filed on Oct. 30, 2020, entitled “Housing for a ConformalWearable Battery,” now abandoned and U.S. application Ser. No.17/086,132 filed on Oct. 30, 2020, entitled “Impact Absorbing Member fora Conformal Wearable Battery,” now U.S. Pat. No. 10,950,913 which arebeing filed concurrently with this application and all of which areherein incorporated by reference in their entirety.

FIELD

Aspects described herein generally relate to portable electrical powerstorage systems. More specifically, aspects of this disclosure relate toflexible printed circuit boards providing conductive paths for a matrixof battery cells.

BACKGROUND

Portable battery systems may be utilized to provide mobile and/or remotelocation electrical power. Integrated communications equipment and/orweapons gear utilized, for example, by law enforcement and/or militarypersonnel requires increasingly high levels of power storage carriedproximate the user's body. Methods of increasing power storagecapability in a device, such as a conformal wearable battery (CWB) is toinclude additional battery cells and/or use higher capacity batterycells. However, these solutions may unacceptably increase the sizeand/or weight of the resulting systems, reducing mobility.

In addition, batteries may come in different shapes and sizes dependingon their intended usage. Some batteries may be arranged as packages ofbattery cells that are assembled together to provide a predeterminedpower output. These battery packages may be arranged in a durable andsealed housing to protect the batteries from damage. In some instances,the battery packages may be desired to flex or bend to accommodate theirintended usage.

SUMMARY

Aspects of the disclosure provide solutions that address and overcometechnical problems associated with minimizing size of a portable batterysystem (e.g. a conformal wearable battery system).

A need has been recognized within the mobile electrical power storageindustry for increasing power capacity while improving an overall usersafety of these systems while simultaneously reducing their size andweight.

A matrix of battery cell modules includes a flexible printed circuitboard assembly (PCBA) for a conformal wearable battery (CWB) with aplurality of attachment sections for each of a plurality of batterycells that are arranged in a grid-like pattern on a same side of theflexible PCBA. Control and/or monitoring circuitry for the CWB may beprovided in a circuitry module. The flexible PCBA is configured to foldalong a bend axis so that the flexible PCBA is folded approximately inhalf. When affixed to the flexible PCBA, the plurality of battery cellmodules and the circuitry module form a grid of physical components.When folded, the flexible PCBA forms a three-dimensional grid ofphysical components comprising at least the battery cell modules.

Aspects of this disclosure may relate to a conformal wearable batterythat may include a plurality of battery cells and a flexible printedcircuit board assembly (PCBA). The flexible PCBA may include a pluralityof physical connection sections disposed in a grid like pattern, whereineach of the plurality of battery cells is physically affixed to theflexible PCBA at a corresponding physical connection section of theplurality of physical connection sections, a bend axis disposed betweentwo parallel physical connection sections, wherein the bend axisfacilitates folding of the flexible PCBA in half. Additionally, theflexible PCBA may include a plurality of first cut-outs disposed alongthe bend axis, wherein each first cut-out of the plurality of firstcut-outs is disposed parallel to the bend axis and a plurality of secondcut-outs disposed across the bend axis, wherein each second cut-out ofthe plurality of second cut-outs are disposed perpendicular to the bendaxis.

In some cases, the conformal wearable battery may include a firstplurality of electrical connections each connecting a cathode of acorresponding battery cell of the plurality of battery cells and secondplurality of electrical connections each connecting an anode of thecorresponding battery cell of the plurality of battery cells toelectrical conductors of the flexible printed circuit board assembly.Further, the conformal wearable battery may include a plurality ofbattery cells, at least one circuitry module configured to control andmonitor charging and discharging of the plurality of battery cells, anda flexible printed circuit board assembly (PCBA). The flexible PCBA mayinclude a plurality of physical connection sections disposed in a gridlike pattern, wherein each of the plurality of battery cells and the atleast one circuitry module is physically affixed to the flexible PCBA ata corresponding physical connection section of the plurality of physicalconnection sections.

Aspects of this disclosure may relate to a conformal wearable batterythat may include a flexible PCBA that includes a first plurality ofelectrical connections each connecting a cathode of a correspondingbattery cell of the plurality of battery cells and second plurality ofelectrical connections each connecting an anode of the correspondingbattery cell of the plurality of battery cells to electrical conductorsof the flexible printed circuit board assembly. The conformal wearablebattery may include a plurality of battery cells and at least onecircuitry module that, when affixed to the flexible PCBA, forms a matrixof physical components. The matrix of physical components may be amatrix of at least two rows and at least two columns. The conformalwearable battery may further include at least one connector configuredto provide an electrical power connection from internal circuitry of theconformal wearable battery to an external device to be powered. Aspectsof this disclosure may relate to a conformal wearable that may includethe plurality of battery cells, where the at least one connector, andthe at least one circuitry module, when affixed to the flexible PCBA,comprises a matrix of physical components.

Aspects of this disclosure may relate to a conformal wearable batterythat may comprise a bend axis that is a center of the grid like patternof the physical connection sections when the flexible PCBA is unfolded.The conformal wearable battery of the illustrative example may include aflexible PCBA having each of the plurality of battery cells physicallyattached to a first side of the flexible PCBA. The conformal wearablebattery may include the flexible PCBA having each of the plurality ofbattery cells physically attached to a first side of the flexible PCBAand each of the plurality of battery cells electrically connected to theflexible PCBA on a second side of the flexible PCBA that is opposite thefirst side. The conformal wearable battery of the illustrative examplemay include the flexible PCBA having the plurality of battery cellsdisposed on an outside surface of the flexible PCBA, when the flexiblePCBA is in a folded configuration.

Aspects of this disclosure may relate to a plurality of battery cellsthat are arranged in a three-dimensional grid pattern. The conformalwearable battery of the illustrative example may include a sealedflexible housing wherein the flexible PCBA is disposed within aninterior cavity of the sealed flexible housing and wherein the flexiblePCBA is in a folded configuration.

Aspects of this disclosure may relate to a system that may include aplurality of battery cell modules and a flexible printed circuit boardassembly (PCBA). The flexible PCBA may further include a plurality ofbattery cell connection sections disposed in a grid-like pattern along afirst surface of the flexible PCBA where each of the plurality ofbattery cell modules is electrically attached to the flexible PCBA on asecond surface of the flexible PCBA in a grid-like pattern, wherein thesecond surface is opposite the first surface. Aspects of this disclosuremay relate to the system that may further include a housing, wherein theflexible PCBA, when in a folded configuration, is located within thehousing. Aspects of this disclosure may relate to the illustrativesystem that may include a plurality of battery cell modules, where eachof the plurality of battery cell modules includes a battery cell and anattenuating member made of a resilient material. Each battery cell maybe a lithium-ion battery cell. The illustrative system may include aplurality of battery cells arranged in a three-dimensional grid patternwhen the flexible PCBA is in a folded configuration.

Aspects of this disclosure may relate to an illustrative flexibleprinted circuit board assembly (PCBA) may include a plurality of batterymodules physically affixed to the flexible PCBA, where the plurality ofbattery modules is arranged in a grid-like pattern and a bend axis nearan approximate mid-point of the flexible PCBA. When the flexible PCBA isbent along the bend axis, the flexible PCBA is in a folded configurationand, when the flexible PCBA is in a folded configuration, the pluralityof battery modules is disposed in a three-dimensional grid-like pattern.

Aspects of this disclosure may relate to a plurality of flexiblesections of the flexible PCBA, were the flexible sections may allow forthe flexible PCBA to flex between adjacent rows and adjacent columns ofbattery modules. The illustrative flexible PCBA may include at least onecircuitry module that comprises a portion of the grid-like pattern.

Additional aspects of this disclosure may relate to a conformal wearablebattery (CWB) including a plurality of battery cells, where each batterycell includes a pair of electrically conductive elements that correspondto either a cathode or an anode of each battery cell. The CWB may alsoinclude a flexible printed circuit board (PCB) that includes a pluralityof physical connection sections disposed in a grid like pattern on afirst side of the flexible PCB, where each of the plurality of batterycells is disposed at a corresponding physical connection section of theplurality of physical connection sections. The flexible PCB may furtherinclude a plurality of electrical connection pads linearly disposed on asecond side opposite the first side of the flexible PCB, the pluralityof electrical connection pads comprising an electrically conductivesurface coating. The pair of electrically conductive elements may extendsubstantially parallel to and along the second side of the flexible PCB,and each electrically conductive elements may be connected to acorresponding electrical connection pad of the plurality of electricalconnection pads on the second side of the flexible PCB forming anelectrical connection.

Aspects of the disclosure may relate to the plurality of battery cellscomprising pouch cell packaged polymer lithium-ion battery cells whereeach battery cell of the plurality of battery cells is physicallyattached to the first side of the flexible PCB.

Aspects of the disclosure may relate to a conformal wearable batterywhere the flexible PCB includes a plurality of cutouts extending throughthe flexible PCB, where at least one cutout of the plurality of cutoutsis located adjacent to an electrical connection pad of the plurality ofelectrical connection pads. In some cases, each conductive element ofthe pair of electrically conductive elements may extend through acorresponding cutout of the plurality of cutouts.

Aspects of the disclosure may relate to a conformal wearable batterywhere the electrically conductive surface coating comprises anelectroless nickel immersion gold (ENIG) surface coating and/or alead-free immersion silver surface coating.

Aspects of the disclosure may relate to forming an electrical connectionbetween each electrically conductive element of the pair of electricallyconductive elements and the corresponding electrical connection pad ofthe plurality of electrical connection pads with a weld. In some cases,the weld is formed using a laser welding process. In some cases, theweld is formed using an ultrasonic welding process.

Aspects of the disclosure may relate to a conformal wearable batterywhere a connection pad of the plurality of electrical connection padshas a width that is within a range of 1.8 times and 3 times a width ofan electrically conductive element of the pair of electricallyconductive elements and/or where a height of an electrical connection iswithin a range of 1.2 to 3 times a thickness of an electricallyconductive element of the pair of electrically conductive elements. Insome cases, a connection pad of the plurality of electrical connectionpads may have a circular shape with a diameter that is within a range of1.8 times and 3 times a width of an electrically conductive element ofthe pair of electrically conductive elements.

Aspects of the disclosure may relate to a system including a firstplurality of battery cells and a second plurality of battery cells and aflexible printed circuit board (PCB). In some cases, the first batterycell of the first plurality of battery cell includes a first pair ofelectrically conductive elements and the second battery cell of thesecond plurality of battery cell includes a second pair of electricallyconductive elements. The flexible PCB may include a plurality of batterycell connection sections disposed in a grid-like pattern along a firstsurface of the flexible PCB, a plurality of cutouts disposed adjacentand parallel to an edge of the plurality of battery cell connectionsections, and a plurality of electrical connection pads disposed on asecond surface of the flexible PCB opposite the first surface. In somecases, the plurality of cutouts may be arranged as multiple pairs ofcutouts arranged adjacent a majority of the plurality of battery cellconnection sections and/or a majority of the plurality of electricalconnection pads may be arranged adjacent the plurality of cutouts, andwhere the plurality of electrical connection pads may include anelectrically conductive surface coating. In some cases, an electricallyconductive element of the first pair of electrically conductive elementsmay wrap around an edge of the flexible PCB and may extend along thesecond surface of the flexible PCB such that the electrically conductiveelement of the first pair of electrically conductive elements may beconnected to a corresponding electrical connection pad of the pluralityof electrical connection pads forming a first electrical connection. Insome cases, an electrically conductive element of the second pair ofelectrically conductive elements may extend through a cutout of theplurality of cutouts such that each electrically conductive element ofthe second pair of electrically conductive elements may be connected toa corresponding electrical connection pad of the plurality electricalconnection pads forming a second electrical connection.

Aspects of this disclosure may relate to a flexible printed circuitboard assembly (PCBA) that may include a flexible printed circuit board(PCB) and a plurality of battery cell modules physically affixed to thefirst side of the flexible PCB. The flexible PCBA may have a first sideand a second side opposite the first side, where a plurality ofelectrical connection pads may be disposed on the second side of theflexible PCB. The plurality of electrical connection pads may bearranged in multiple pairs of electrical connection pads. In some cases,the plurality of electrical connection pads may include an electricallyconductive surface coating. The flexible PCBA may include a plurality ofcutouts linearly disposed in the flexible PCB and adjacent tocorresponding electrical connection pads. In some cases, the pluralityof battery cell modules may be arranged in a grid-like pattern andcomprise pouch cell packaged polymer lithium-ion and each battery cellmodule of the plurality of battery cell modules may include a pair ofelectrically conductive elements that extend substantially parallel tothe second side of the flexible PCB and may be configured to connect tocorresponding electrical connection pads of the plurality of electricalconnection pads to form an electrical connection for each battery cellmodule.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is illustrated by way of example and not limitedin the accompanying figures in which like reference numerals indicatesimilar elements and in which:

FIG. 1 shows a first view of an illustrative flexible printed circuitboard for an illustrative conformal wearable battery system according toaspects of the present disclosure;

FIG. 2 shows a second view of the illustrative flexible printed circuitboard for the illustrative conformal wearable battery system accordingto aspects of the present disclosure;

FIG. 3 shows a partial second view of the illustrative flexible printedcircuit board including markings for placement of two battery modules;

FIG. 4 shows a first view of the illustrative flexible printed circuitboard folded along the bend line according to aspects of the presentdisclosure;

FIGS. 5A-5C show first views of flexible printed circuit boardassemblies (PCBA) before folding along the bend line according toaspects of the present disclosure;

FIG. 6 shows a second view of the flexible PCBA before folding along thebend line according to aspects of the present disclosure;

FIG. 7 shows a partial first view of the flexible printed circuit boardassembly showing a partial arrangement of adjacent battery cell moduleswhen attached in an array or matrix format on the flexible PCBAaccording to aspects of the present disclosure;

FIG. 8 shows a side view of the flexible PCBA before folding along thebend line according to aspects of the disclosure;

FIG. 9 shows a side view of the flexible PCBA after folding along thecenter line according to aspects of the disclosure;

FIG. 10 shows a first view of the flexible printed circuit boardassembly after folding along the bend line according to aspects of thedisclosure;

FIG. 11 shows a partial side view of the flexible PCBA after foldingalong the bend line;

FIG. 12 shows a partial first view of the flexible PCBA after foldingalong the bend line according to aspects of the disclosure;

FIGS. 13A-13D show different views of an illustrative battery cell 1300according to aspects of the disclosure;

FIGS. 14A-14E show illustrative views of a battery cell modulecomprising a battery cell and a battery cell attenuating memberaccording to aspects of the disclosure;

FIGS. 15A-15E show partial illustrative views of at least one batterycell module being attached to the flexible PCBA according to aspects ofthe disclosure;

FIGS. 16 and 17 show different perspective views of a battery cellmatrix or grid associated with a flexible PCBA according to aspects ofthe present disclosure;

FIGS. 18A-18D show different side views of the flexible PCBA from aperspective of each of four different edges according to aspects of thisdisclosure;

FIGS. 19 and 20 show partial views of the illustrative PCBA of oppositesides near the connector module, according to aspects of thisdisclosure;

FIGS. 21 and 22 illustrate an illustrative conformal wearable battery(CWB) including a matrix of internal battery cell modules according toaspects of this disclosure; and

FIG. 23 shows an illustrative installation process for attaching eachbattery cell module to the flexible PCB according to aspects of thisdisclosure.

DETAILED DESCRIPTION

In the following description of various illustrative arrangements,reference is made to the accompanying drawings, which form a parthereof, and in which is shown, by way of illustration, variousarrangements in which aspects of the disclosure may be practiced. It isto be understood that other arrangements may be utilized, and structuraland functional modifications may be made, without departing from thescope of the present disclosure. It is noted that the accompanyingdrawings may not be drawn to scale.

It is noted that various connections between elements are discussed inthe following description. It is noted that these connections aregeneral and, unless specified otherwise, may be direct or indirect, andthat the specification is not intended to be limiting in this respect.

A rechargeable conformable wearable battery (CWB) assembly may be wornby a user to power electronic devices that the user carries. The CWBassembly may be subjected to environmental conditions that the user isalso subjected to. The CWB may be subjected to a multitude ofenvironmental conditions such as harsh shock and vibration, moistureexposure, and extreme temperatures. The CWB may have a sealed housingthat is sealed to facilitate longer battery life and utility for theuser regardless of environmental conditions that the CWB may encounter.To provide a desired power output, the CWB may include a plurality ofbattery cells, each with a rated power capacity and when electricallyconnected, may allow the CWB to provide a desired power output andwithin a specified size range and/or weight range.

A CWB may include an array of a first quantity of battery cells disposedadjacent to one another in a horizontal direction and a second quantityof battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing (e.g., a pouch, a metal enclosure, etc.) separate fromother battery cells. A battery cell as described herein may include aplurality of individual battery cell elements that are electricallyconnected together to form a compound battery cell that electricallyperforms as a single unit. Each of the battery cell housings may bephysically connected to adjacent battery cell housings by flexibleelements (e.g., a flexible printed circuit board), thereby facilitatinga surface outline or shape of the array of battery cells to generallyconform to a surface outline or shape of a user wearing the CWB. Forexample, the CWB may include one or more flex lines along which the CWBmay flexibly conform to a shape of an object adjacent to the CWB, suchas a portion of a user's body. One or more of the battery cell housingsmay include a positive-charge electrical terminal and a negative-chargeelectrical terminal that are electrically connected with the batterycell within an interior of the battery cell housing and provideelectrical power to electrical devices disposed exterior to the batterycell housing. Electrical terminals of a plurality of the battery cellsin the array of battery cells may be connected together to routeelectrical current through the plurality of the battery cells and a setof positive-charge and negative-charge electrical terminals that areshared among the plurality of the battery cells. The positive-chargeelectrical terminal and the negative-charge electrical terminal mayprovide an electrical current that passes through an electricallyconductive path, for example, through an electronic device, via transferof electrons through the electrically conductive path between thepositive-charge electrical terminal and the negative-charge electricalterminal on the exterior of the battery cell housing. The CWB mayinclude a set of positive-charge and negative-charge electricalterminals that are shared among the plurality of the battery cells ofthe array of battery cells. The plurality of the battery cells may beelectrically coupled together, for example, in series or in parallel.

In some cases, the battery cell may be formed of electrodes and a solidelectrolyte that are stacked in layers or laminations and enclosed in afoil envelope housing, which is then sealed. The positive-chargeterminal and the negative-charge terminal may each include a conductiveregion that passes between the interior of the cell housing and theexterior of the cell housing at an outer wall of the casing. Theconductive region may be affixed and electrically connected to thebattery cell in an interior of the cell housing at one end, pass throughthe sealed wall of the casing, and affix to conductive elements thatelectrically couples with electrical devices at an exterior of the cellhousing.

The CWB housing may be formed of a molded casing that may be createdthrough a molding process, such as an injection molding process. Themolded CWB housing may be formed of a polymeric material, for example.The CWB housing may be sealed to prevent ingress of solid materialand/or liquid material, for example, according to an IP67 rating, IP68rating, or other ingress protection rating. In some cases, the CWBhousing may be created through connecting at least two housing portionsinto a complete sealed housing to encase the battery cells within thecasing. The positive-charge terminal and the negative-charge terminalmay each include a conductive region that passes between the interior ofthe CWB housing and the exterior of the CWB housing.

In some cases, the CWB may be provided in a form factor easily carriedby a person, such as within a pocket or with other means of securing theCWB assembly to a person's clothing, uniform, or the like. To providethe specified power output, while also providing flexibility forconforming to a shape of person's body or equipment when carried, thematrix of battery cells may be arranged on, and affixed to, a flexibleprinted circuit board. To fit within the housing of the CWB assembly,the flexible printed circuit board assembly may be configured to befolded along an axis (e.g., a center line), such that battery cellmodules may be on an exterior surface of the flexible printed circuitboard assembly closest to the housing, while the electrical connectionsmay be made on an interior surface of the folded printed circuit boardassembly. An electrical insulator (e.g., foam, insulating tape, etc.)may be placed between the folded sections to provide electricalinsulation for the electrical contacts.

FIG. 1 shows a first view of an illustrative flexible printed circuitboard (PCB) 100 for an illustrative CWB according to aspects of thepresent disclosure. The flexible PCB may be configured to provide powerand/or electrical signals from a plurality of battery cells and/or othercomponents of a CWB. The flexible PCB 100 may be formed of one or morelayers of a flexible polymer or plastic material, such as a polyimide orother such flexible substrate. In some cases, markings showing locationsto facilitate placement of battery cells may be included on a surface ofthe flexible PCB 100, such as those formed through a silk-screeningprocess, or other like method. Electrical conductors may be included inone or more layers of the flexible PCB. In some cases, electricalconductors may be configured as a conductive pattern (e.g., a copperoverlay, a conductive ink, etc.) on the surface of the substrate of theflexible PCB 100. In some cases, exposed conductive features (e.g.,conductors, a bare copper surface, a bare aluminum surface, etc.) may becoated with a coverlay substance, such as an electrical insulator. Forconductive portions of the flexible PCB not covered with a coverlay, thesurface may be plated, such as with an electroless nickel immersion gold(ENIG) finish, a lead-free immersion silver finish or other substanceswith improved conductive properties.

The flexible PCB 100 may be configured to bend along a bend line 105located at or near a center line of the flexible PCB 100 such as to forma bend of a desired angle (e.g., a 180-degree bend). One or moreelongated cut-outs may be disposed parallel to the bend line 105 (e.g.,cut-out 110) and/or perpendicular to the bend line 105 (e.g., cut-out120), where the cut-outs perpendicular to the bend line 105 may bealigned with a flex line (e.g., a flex line 125 a, a flex line 125 b, aflex line 125 c, etc.) perpendicular to the bend line 105. In somecases, the flex line may correspond to a section of the flexible PCB 100located between rows of components (e.g., battery cells) along which theCWB may bend during use. Such cut-outs may provide additionalflexibility to the flexible PCB 100 to allow for easier formation of thedesired bend angle (e.g., the 180-degree bend) such as by folding theright half of the flexible PCB 100 over the left half of the flexiblePCB 100 and/or flexing along one or more adjacent flex lines. In theillustrative example, relief cuts, such as the cut-out 110 may be formedas a rounded elongated rectangular cutout and the cut-out 120, may beformed in a generally obround shape (e.g., two substantiallysemi-circular sections connected by a rectangular section). Asmentioned, the elongated rounded rectangular cut-outs (e.g., cut-out110) parallel to the bend line 105 may reduce stress on the plasticsubstrate when forming the about 180-degree bend. Additionally, theobround-shaped cut-outs (e.g., cut-out 120) may reduce stresses placedon the flexible PCB substrate during use, such as by reducing stressesalong a line of deformation (e.g., the flex line 125 a, a flex line 225a of FIG. 2, etc.) between battery cells.

In some cases, additional cut-outs may be included to reduce stressesalong the flex line (e.g., the flex line 125 a, the flex line 125 b, theflex line 125 c), such as at an edge of the flexible PCB 100, such as acorner notch 190 a located near a corner formed in the edge of theflexible PCB 100 near a flex line and/or a notch 190 b located along anedge of the flexible PCB 100 and aligned near a flex line. By reducingthe bending stress at locations along the bend line, a probability of acatastrophic failure of the substrate (e.g., cracking, delamination, andthe like) is reduced. While cut-out 110 is shown as a roundedrectangular shape and the cut-out 120 is shown as an obround shape,other shapes may be used to remove weight and/or to reduce stress due tobending and/or flexing of the flexible PCB 100. While an obround shapeis shown on the illustrative example, other cut shapes may be used. Suchother shapes may include circular cuts which may be used, for example,for removing more weight, oval cuts which may provide additional stressrelief, for example, based on the curves, elongated slots which, forexample, may be similar to the rectangular cuts but with even more fileton corners that may reduce additional stresses, a dog-bone shape (e.g.,two substantially circular sections connected by a rectangular section),and/or the like.

The flexible PCB 100 may also include a plurality of conductive pads(e.g., pads 150) to provide electrical connection for the cathode andanode of each battery module connected to the flexible PCB 100. Forbattery cells located near an edge of the flexible PCB 100, the cathodean anode connectors may be bent over the edge of the flexible PCB 100.For battery cells located away from the edge of the flexible PCB, aplurality of cut-outs (e.g., the cut-out 140) are located near acorresponding pad 150 to allow for solder or weld connection of thebattery cathode or anode connector to the flexible PCB 100.Additionally, the flexible PCB 100 may include charging connectionportion 190 that may be used to connect to one or more charging tabs onan exterior portion of a case of the conformal wearable batteryenclosure and/or a flexible connector portion 160 that may include oneor more flexible connectors to connect to additional circuitry, such asa control module, a display module, or the like). The flexible PCB 100may also include one or more semi-circular cut-out sections 180 toprovide an area of low mechanical stress at an interior portion of theflexible PCB 100. In some cases, an electrical component 280, shown inFIG. 2, (e.g., a thermistor) may be physically connected to the flexiblePCB 100 in this area such that the electrical component does not receivestress loads while the CWB is flexed during use. Such stress loads,without the stress relief provided by the semi-circular cut-outs, maycause the electrical component to detach from the flexible PCB 100.

FIG. 2 shows second view of the illustrative flexible printed circuitboard 100 for the illustrative conformal wearable battery systemaccording to aspects of the present disclosure. In some cases, physicalconnection locations for each battery cell may be marked (e.g., batterycell location 210, 230, etc.). Additionally, one or more physicalconnection locations for electrical circuitry may be marked or unmarked(e.g., circuitry module location 240, circuitry module 250, etc.). Theflexible PCB 100 may also include one or more cut-out areas of theflexible PCB 100 (e.g., cut out area 260, cut out area 270, etc.) toaccommodate inclusion of electrical connectors (e.g., flexibleconnection portion 160, etc.), such as those provided to provide, and/orreceive, information and/or electrical power to/from one or moreexternal devices. In some cases, one or more of the battery cellconnection locations and/or the connection locations for electricalcircuitry may include a rigidizing material, or may be otherwisereinforced.

The battery cell locations, circuitry module locations, cut outs, and/orelectrical connection locations may be provided in a matrix or gridpattern on an outward facing surface or front side of the flexible PCB100. For example, the battery cell locations may be arranged in rows,such as battery cell row 232, battery cell row 234, and the like, an/orin columns, such as battery cell column 233, battery cell column 235,and the like. Additionally, one or more of the cut-out area 260, thecut-out area 270, the circuitry module location 240, the circuitrymodule 250, and the like may be aligned in a same row (e.g., row 236).In some cases, one or more of the cut-out areas, circuitry module areas,and/or electrical connection areas may be located in different rowsand/or columns of the matrix or grid pattern. In some cases, a matrix orgrid pattern may include a combination of one or more of the batterycell locations, the one or more circuitry module locations and/or thecut-out locations. In the illustrative configuration shown in FIG. 2,the matrix or grid pattern may include 36 battery cell locations, 2circuitry module locations, and two cut-out locations, where one of thecut-out locations accommodates the flexible connection portion 160.

In some cases, each battery cell location 230 may be associated with apair of cut-outs for the anode and cathode connections, as discussedabove. Here, a battery cell module may be physically attached to thesubstrate of the flexible PCB 100, such as by use of an adhesivematerial (e.g., glue, tape, etc.) or other such bonding material. Thecathode and anode connection tabs may be inserted through acorresponding cut-out 140 so that the connection tabs may be soldered,welded, or otherwise connected to the connection pad 150 on the oppositeside of the flexible PCB 100. Additional to a plurality of battery celllocations (e.g., 36 battery cell locations), the flexible PCB 100 mayinclude one or more locations, marked or unmarked on the flexible PCB100, where electronic circuit modules may be attached, such as theelectronic circuit location 240, the electronic circuit location 250,and the like. For example, electronic circuit modules may be physicallyattached to the substrate of the flexible PCB 100, such as by use of anadhesive material (e.g., glue, tape, etc.) or other such bondingmaterial. Further, the flexible PCB 100 may include a cut-out section260 that is of similar size to a battery cell location 230 that may alsobe inclusive of at least a portion of an area associated with one ormore flex lines (e.g., a flex line 125 a, a flex line 225 b), and thelike. The cut-out section 270 may be configured to correspond with theflexible connector portion 160.

In some cases, the electrical connection cut-outs (e.g., cut-out 140)and/or end cut outs (e.g., cut-out 190 a, 190 b) may be disposed near oroffset from the flex line 125 b between rows of battery cell locations230 at a distance configured to reduce or eliminate stresses applied tothe cell tabs (e.g., a cathode connection tab, an anode connection tab)of each battery cell. Because the battery cell locations are reinforcedor otherwise stiffened by the battery modules, the flex lines 225 a-iand 125 a-c may allow for the CWB to be flexed within a designed rangeof motion, when in use. To provide stress relief along these flex linesbetween the rigid battery cell portions, the obround-shaped cut-outs 120are disposed within each flex line 225 and may be aligned with a portionof the battery cell connection cut-outs (e.g., cut-out 140) and the edgecut-outs 190 a, 190 b may be aligned to the flex lines 225 and locatedat an edge of the flexible PCB 100.

FIG. 3 shows a partial second view of the illustrative flexible printedcircuit board 100 including markings for placement of two batterymodules, cut-outs through which battery cell tabs are placed forconnection on the opposite side, and cut-outs providing strain reliefalong a center line and/or along a flex line perpendicular to the centerline according to aspects of the present disclosure. As discussed above,the rectangular cut-out 110 may be disposed centered on and parallel tothe bend line 105 at the center of the flexible PCB 100, where at leasta portion of the cut-out 110 may be disposed underneath a battery cellmodule when installed. In an illustrative example, a battery cellconnection area 330 may be about 50 mm in length along an edge 332 andabout 35 mm in width along an edge 334. In some cases, along the flexline 105, the cut-out 110 may be located near a mid-point of the batterycell connection area 330.

In the illustrative example of FIG. 3, a first edge 312 a of the cut-out110 may be located at a first distance (e.g., about 11.5 mm) from afirst edge of the battery cell connection area 330, the second edge 312b of the cut-out 110 may be located at a second distance (e.g., about11.5 mm) from the second edge of the battery cell connection area 330,and the length of the cut-out 110 between the first edge 312 a and thesecond edge 312 b may be a first dimension (e.g., about 25 mm). A widthof the cut-out between the left edge 314 a and the right edge 314 b maybe a second dimension (e.g., about 4.5 mm), and a radius of each roundedcorner 316 may be a third dimension (e.g., about 1.1 mm). The specificdistances and/or dimension are given for illustrative purposes and otherdistances and/or dimensions may be contemplated within the scope of thisdisclosure.

The illustrative obround-shaped cut-out 120 may be formed as arectangular area 322 b connecting two semi-circular areas 328 a and 328b. For example, the obround-shaped connector 120 may be centered on andperpendicular to the bend line 105. The rectangular area 322 b maylarger than the distance between adjacent battery cell connection areas.Each semi-circular area 238 a and 328 b may overlap at least a portionof adjacent battery connection areas.

The illustrative battery connection cut-out 140 may be formed as anelongated oval shape, such as an illustrative shape of about 1.5 mm high(e.g., between edge 342 a and edge 342 b) and having a distance of about6 mm between a center point of each circular end portion (e.g., point344) and an overall length of about 9 mm. In some cases, the edge 342 bof the cut-out 140 may align with a center line through the obroundshaped cut-out 120. Additionally, the obround-shaped cut-out 120 may belocated a distance (e.g., about 4 mm) from the battery connectioncut-out 140.

Spacing of the battery cell connection areas may be configured to allowfor construction of the finished CWB and/or for a specified amount ofmovement (e.g., flexing, bending, etc.) of the CWB when in use. Forexample, the spacings of the battery cells relative to flex lines 225a-225 i and/or flex lines 125 a-125 c may allow for an amount of flexingor bending of the CWB as defined in a specification such as, forexample, MIL-PRF-32383/4A, while maintaining structural integrity. Forexample, the spacings of battery cell connection areas may allow forbending of the CWB such that a center section of the CWB to bend whilethe edges of the CWB are held stationary. In some cases, the edges ofthe CWB may pivot in the direction of the bend. Upon application offorce to the center section of the CWB, e.g., at a distance equidistantbetween centerline edges of the CWB, the center portion of the CWB mayflex up and/or down a specified distance (e.g., at least one inch,between 1 inch and two inches, etc.). For example, spacing of thebattery cell connection areas 330 may be distributed as a grid or matrixpattern such that spacing between allows for uniform distribution of theadjacent battery cell connection areas, along column of battery celllocation areas (e.g., column 235) and/or along rows of battery cellconnection areas (e.g., row 234). In some cases, spacing of adjacentbattery cell connection areas adjacent to a central flex line (e.g.,flex line 105) may differ such as to allow for forming a 180-degree bendin the flexible PCB 100. In the illustrative example shown in FIG. 3,spacing of adjacent columns of battery cell connection areas (e.g.,column 233, column 235) are illustrated in the spacing between sides 332a and 332 a′ of adjacent battery cell areas and has a distance of about2.3 mm. As mentioned, to allow for formation of a 180-degree bend in theflexible PCB 100, spacing along a central line (e.g., flex line 105,flex line 225 e) may be the same as those between other adjacent columnsof battery cell connection areas or may be different. In theillustrative example of FIG. 3, spacing between side 332 and 332′ may beabout 2.68 mm. Spacing between adjacent rows of battery cell connectionareas may be configured to allow for flexing and/or bending of the CWBand/or to facilitate electrical connection of a battery cell to theflexible PCB 100. In the illustrative example of FIG. 3, spacing ofadjacent rows of battery cell location areas (the row 232, the row 234,the row 236, the row 238) are illustrated in the spacing between sides334 and 334′ of adjacent battery cell areas and has a distance of about4.4 mm. The specific distances and/or dimension are given forillustrative purposes and other distances and/or dimensions may becontemplated within the scope of this disclosure.

FIG. 4 shows a first view of the illustrative flexible printed circuitboard 100 folded along the bend line 105 according to aspects of thepresent disclosure. For example, a 180-degree bend 405 may be formedalong the bend line 105, such as when a left half of the flexibleprinted circuit board 100 is folded over a right half of the flexibleprinted circuit board 100 such that the battery modules are located onthe exterior portion of the folded flexible printed circuit board 100and the electrical connections for the battery modules are disposed onan interior portion of the folded flexible printed circuit board 100. Adiameter of the bend 405 corresponds the length of the rectangularportion of the obround-shaped cut-out 120. In the illustrative example,the diameter of the bend 405 is about 2.25 mm.

FIGS. 5A-5C show first views of a flexible printed circuit boardassembly (PCBA) 500 before folding along the bend line 105 according toaspects of the present disclosure. As shown in FIG. 5A, electricallyconductive cathode tabs and anode tabs 540 extend from correspondingbattery cell modules through corresponding cut-outs 140 so that eachconductive tab 540 may be soldered, welded or otherwise connected to acorresponding electrical connection pad 150 forming an electricalconnection for each battery cell to the flexible PCBA 500. Theelectrical connection pads 150 may include an electroless nickelimmersion gold (ENIG) surface coating, a lead-free immersion silversurface coating, or other coating that improves electrical connectiondurability and conductivity between the electrically conductiveconnection tabs and the electrical connection pads. The connection pad150, and/or its surface coating, may allow for individual joining tofacilitate connection of aluminum, nickel, or copper battery tabs 540.The electrically conductive connection tabs 540 may be connected tocorresponding connection pads 150 using spot welding, ultrasonicwelding, laser welding, and/or other welding or connection technique toreduce an amount of heat applied to the surface during the attachmentprocess, an amount of material needed to form the joint while alsoincreasing quality and/or a rate of production compared to typicalsoldering.

Because of the compact nature of the CWB and the folded configuration ofthe flexible PCBA 500, the electrical connection between the connectionpads 150 and the battery connection tabs 540 may be minimized withrespect to the height of the overall connection relative to the inwardfacing surfaces 520A, 520B. For instance, by using a welding techniquethat applies localized heat over a smaller amount of time compared totraditional soldering, the amount of material, and heat, needed to forma solid connection may be reduced. This means that the outward facingsurface of the connection tab 540 may be have little to no additionalmaterial on it after being secured to the pad 150. Further, byminimizing applied heat during the connection process, a probabilitythat the folded flexible PCBA 500, the battery cell(s), or othercomponent near the connection site may be damaged is similarly reduced.In some cases, the joint may be formed using only by joining thematerial of the pad 150 and the material of the connection tab 540without the addition of solder, weld filler, or any additional material.By minimizing the amount of material in the joint, the height, H1, ofthe connection may be controlled to reduce the overall thickness of thefolded flexible PCBA 500. As shown in FIG. 8, the height, H1, may bedefined as the distance between an outward facing surface of eachconnection tab 540 and the rear or inward facing surface 520A or 520B ofthe flexible PCBA 500. For example, the height, H1, of the joint may beapproximately 1.5 times the thickness of the connection tab 540 or maybe within a range of 1.2 to 3 times the thickness of the connection tab540.

As can be seen in FIGS. 5B and 5C, cathode tabs and anode tabs (e.g.,tab 540, tab 542, etc.) extend from corresponding battery cell modulesthrough a cut-out 140 so that each tab 540 may be soldered, welded orotherwise connected to the electrical connection pad 150 forming anelectrical connection for each battery cell. In some cases, for batterycells located near an edge of the flexible PCBA 500, the battery tabs(e.g., tab 542) may be folded over an edge of the flexible PCB 100 to bephysically and electrically connected to the electrical circuitry of theflexible PCBA 500. To protect against short circuits and/or to provideadditional protection and/or structural integrity for the CWB, whilemaintaining flexibility of the overall assembly, an insulating material552, 554 (e.g., a foam material, a polymeric material, etc.) may beplaced over a first half of the flexible PCBA 500 before folding. Theinsulating material 552 may include an insulation cut-out 556 section,where edges of the insulation cut-out 556 may be adjacent to a firstelectrical circuitry module 550, a second electrical circuitry module570, a connector section 560, and/or an output module 580 (e.g., an OLEDdisplay, and LED display, and the like). In some cases, the insulatingmaterial 552 may include one or more cutouts that may align with acutout of the flexible PCB 100, such as cut-out 562, and cut-out 564, asshown in FIG. 5C. In some regions of the flexible PCBA 500, eachconnection tab 540 may extend through a cutout 140 of the flexible PCB100 to attach to its corresponding connection pad 150, while in otherregions connection tabs 540 may extend from its respective battery celland wrap around an upper edge of the PCB 100 before attaching to itscorresponding connection pad 540.

FIG. 6 shows a second view of the flexible printed circuit boardassembly 500 before folding along the bend line 105 according to aspectsof the present disclosure. Here an array of battery cells 610 may bephysically and electrically attached to the flexible PCBA 500. Forexample, each battery cell module 620 of the battery cell array 610 maybe physically attached to a first side of the flexible PCBA 500.Electrical connections of each battery cell module 620 may be passedthrough a cut-out (e.g., the cut-out 140 to allow for an electrical andphysical connection via a corresponding pad 150 on an opposite side ofthe flexible PCBA. Each battery cell module 620 of the array of batterycells may be connected to an electrical circuit of the flexible PCBAcomprising a plurality of conductive paths, where at least a portion ofthe plurality of conductive paths provide redundant pathways for one ofa conductive path electrically connecting the plurality of cathode tabsof the battery cell array 610 or a conductive path electricallyconnecting the plurality of anode tabs of the battery cell array 610.Each battery cell of the battery cell array 610 may be coupled togetherto provide electrical power to a desired electrical load that may beremovable connected to the CWB. A positive terminal or tab of eachbattery cell may be coupled to a positive trace pad of a positive tracebus and a negative terminal or tab of each battery cell may be coupledto a negative trace pad of a negative trace bus such that the pluralityof battery cell modules of the battery cell array 610 may beelectrically coupled in parallel with one another. In some cases, thepositive trace bus and the negative trace bus may each include aplurality of electrical pathways. For example, the positive trace busand the negative trace bus may each be formed as a conductive mesh. Insome cases, the conductive mesh may form a plurality of alternativeconductive paths connecting to the plurality of positive trace pads andnegative trace pads. Should a portion of the alternate conductive pathsof the conductive mesh be damaged, for example by a destructivepenetration to the CWB, a tear, a fracture, or other such damage to theflexible PCB, other alternative conductive pathways of the conductivemesh may be capable of providing electrical current around the damagedarea.

In some cases, one or more of the alternative conductive pathways may beconnected to one of a positive battery cell tab, a negative battery celltab, protection circuitry, data circuitry, clock circuitry and/or othercircuitry associated with operation and/or monitoring of the CWB.Circuitry associated with the battery cell may include battery chargingcontrol circuitry, for example. Conductive pathways may carry electricalcurrent and/or data signals between the battery cell and/or associatedcircuitry within an interior of a CWB housing and one or more contactcomponent accessible on the outside of the CWB housing.

FIG. 7 shows a partial first view of the flexible printed circuit boardassembly 500 showing a partial arrangement of adjacent battery cellmodules (e.g., battery cell module 620) when attached in an array ormatrix format on the flexible PCBA 500. Each battery cell module 620 mayinclude an attenuating member 710 attached to a battery cell 720 suchthat when the battery cell module 620 is physically attached to theflexible PCBA 500, a first side of the battery cell 720 may be adheredor otherwise attached to the flexible PCBA 500 and the attenuatingmember 710 may be attached to an opposite side of the battery cellmodule 720.

As shown, the plurality of battery cell attenuating members 710 may beindividually attached to the outward facing surface of each battery cell720. Each battery cell attenuating member 710 may be positioned betweenthe outward facing surface of the battery cell 720 so that a top surfaceof the attenuating member 710 faces an interior surface of the CWB, whenassembled. In addition, each battery cell attenuating member 710 mayalso contact one of the interior surface of the CWB. In short,attenuating member 710 may be located between the battery cells 720arranged on the flexible PCBA 500, and the battery cell attenuatingmembers 710 may located between the battery cells 720 and the housing ofthe CWB. The attenuating members 710 may help to protect the batterycells 720 by absorbing the forces received by the CWB 10 from anyimpacts or collisions. The battery cell attenuating members 710 may beformed from a visco-elastic material that can attenuate shock andvibration. In some cases, the visco-elastic material may include otherproperties including intumescent properties or other fire blockingand/or suppression characteristics. The visco-elastic material may beformed from a polymeric material such as a polyurethane based materialsuch as Poron®, Sorbothane®, or similar material. In some cases, thebattery cell attenuating members 710 may be made of an electricallyinsulative material.

Each battery cell attenuating member 710 may have an opening 730extending through the thickness of the attenuating member 710. Eachopening 730 may create a cavity between the respective outward facingsurface of the battery cell 720 and one of the interior surfaces of thehousing of the CWB. As the battery cells 720 go through cycles ofdischarging and recharging, the chemical reaction inside the batterycells 720 may cause the battery cells 720 to swell or increase involume. As the battery cells 720 swell, they may expand into the cavitycreated by the opening 730. In some cases, the battery cells 720 mayencounter swelling of less than 4%. In some cases, the battery cells 720may swell in a range between 4% and 10%. In some cases, the batterycells 720 may encounter swelling of about 15% or less. The thickness ofthe battery cell attenuating member 710 may be approximately 10 percentof the thickness of the battery cell 720, or may be within a range of 8percent and 15 percent of the thickness of the battery cell 720. In someexamples, the opening 730 may not extend through the entire thickness ofthe attenuating member 710 creating cavity within attenuating member710. For example, the opening 730 may extend from the rear surfacethrough at least 50 percent of the thickness, or through at least 75percent of the thickness. In these cases, the depth of the cavity may bewithin a range of 4 percent and 15 percent of the thickness of thebattery cell 130.

FIG. 8 shows a side view of the flexible PCBA 500 before folding alongthe bend line according to aspects of the disclosure and FIG. 9 shows aside view of the flexible PCBA 500 after folding along the center lineaccording to aspects of the disclosure. FIG. 10 shows a first view ofthe flexible printed circuit board assembly (PCBA) 1000 after foldingalong the bend line according to aspects of the disclosure. Afterfolding the flexible PCBA 1000, a side of the folded flexible PCBA 500is shown to have a battery cell array or matrix having 19 battery cellmodules 1010 and an opening including a connector section. In thisillustrative example, the battery cell array may be arranged as a 5×4matrix of battery cells and an opening to accommodate the connectorsection. While the 5×4 matrix is shown, other arrangements and/orconfigurations of the battery cell matrix (e.g. a 5×5 matrix, a 4×4matrix, a 4×3 matrix, a 3×2 matrix, a 4×1 matrix, a 3×3 matrix, etc.)may be contemplated within scope of this disclosure. Once the flexiblePCBA 500 is folded, battery cell modules affixed to either half of thefolded flexible PCBA 500 are positioned opposite to a correspondingbattery cell module or a circuitry module.

FIG. 11 shows a partial side view of the flexible PCBA 900 after foldingalong the bend line and FIG. 12 shows a partial first view of theflexible PCBA 900 after folding along the bend line according to aspectsof the disclosure.

FIGS. 13A-13D show different views of an illustrative battery cell 1300(e.g., a pouch cell packaged polymer lithium-ion battery), which may beincorporated into a battery cell module as discussed above. In somecases, a chemical system of battery cell 1300 may include one of alithium cobalt oxide, nickel cobalt manganese, nickel cobalt aluminum,or other such chemical systems. In an illustrative example, thedimensions of the battery cell 130 may be about 43 mm in length, about34 mm in width, and about 6 mm in height, but battery cells of otherdimensions may be used within the scope of this disclosure.Additionally, the battery cell 130 may weigh between 22.5 grams and 24.5grams (e.g., 23.5 grams) and may have an energy storage capacity between1400 mAh and 1500 mAh (e.g., about 1,435 mAh). The size, weight, andenergy storage capacity of each battery cell of the CWB may be designedsuch that the overall size, weight, and energy storage capacity of theflexible PCBA for the CWB meets an energy storage capacityspecification, weight specification, and/or size specification for aCWB. For example, the height, width, and length of each battery cell maybe designed, at least in part, to meet a flexibility requirement of theCWB, such that an assembled CWB may conform, under load, to a 7-inchradius curved surface, such that an edge of the CWB may be capable ofdeflecting, in each direction, at least a specified distance (e.g., 1inch) from a centerline of the CWB. Additionally, the size, and/or shapeof the battery cells may allow for a specified number of battery cells(e.g., about 36 battery cells) and/or configuration of the battery gridsuch that the energy capacity for the CWB may be at least 148 Watt-hours(Wh) (e.g., about 150 Wh, about 170 Wh, about 190 Wh, about 200 Wh,etc.) and/or where the maximum weight of the CWB is less than aspecified maximum weight (e.g., about 2.6 pounds). In some cases, aconfiguration of the battery cells of the CWB may allow the CWB tooutput a voltage between about 10 and about 20 V, (e.g., about 14.8V)within a specified size and/or shape of the CWB. For example, anillustrative CWB may have an overall dimensions of between about 8.5 in.and 9.0 inches (e.g., about 8.7 in.)×between about 7.5 in and 8 in.(e.g., about 7.66 in.)×between about 0.5 in. and 0.8 in. (e.g., 0.70in.).

FIGS. 13A-13D show different views of an illustrative battery cell 1300(e.g., a pouch cell packaged polymer lithium-ion battery), which may beincorporated into a battery cell module 1010 as discussed above. In somecases, a chemical system of battery cell 1300 may include one of alithium cobalt oxide, nickel cobalt manganese, nickel cobalt aluminum,or other such chemical systems. In an illustrative example, thedimensions of the battery cell 1300 may be in a range between about 42mm to about 44 mm (e.g., 43 mm) in length, a range between about 33 mmand 35 mm (e.g., about 34 mm) in width, and in a range between about 5mm and 7 mm (e.g., about 6 mm) in height, but battery cells of otherdimensions may be used within the scope of this disclosure. FIG. 13Dshows an illustrative side view of the battery cell 1300. Whilelithium-ion battery cells in a pouch-cell format are discussed, otherbattery formats or chemistries may be used, such as prismatic batterycells, can-type battery cells, and the like.

In FIGS. 13A-13D, the battery cell tabs 540 may include a cathode tab1302 and an anode tab 1304. The cathode tab 1302 and anode tab 1304 areshown in a bent configuration illustrative of the physical configurationof the cathode tab 1302 and anode tab 1304 for when the battery cell1300 is physically attached to the flexible PCB 100, where the cathodetab 1302 and the anode tab 1304 are placed through corresponding cutouts140 so that the cathode tab 1302 and the anode tab 1304 each may beelectrically connected (e.g., soldered, laser welded, ultrasonic welded,etc.) to a corresponding pad 150. In some cases, the cathode tab 1302may be made of a first material (e.g., copper) and may be clad in asecond material (e.g., aluminum). In some cases, the cathode tab may bemade of a single material (e.g., aluminum, copper, etc.). This claddingarrangement may cause a thickness and/or height of the cathode tab 1302relative to its respective inward facing surface of the PCB 100 to begreater than a thickness or height of the anode tab 1304. The anode taband the cathode tab may be made of or include a similar electricallyconductive metal, such as copper, aluminum, nickel and the like. In theillustrative example of FIG. 13A, opposing edges of the cathode tab 1302and the anode tab 1304 may be positioned approximately 12 mm apart orwithin a range of 10 mm and 15 mm apart. Further, the cathode tab 1302and the anode tab 1304 may have a similar length (e.g., about 12.4 mm)and/or a similar width (e.g., about 4 mm), however, one or moredimensions of the cathode tab 1302 or anode tab 1304 may differ from theother within the scope of this disclosure. FIG. 13A shows a front viewof the battery cell 1300. The terms “top” 1342 and “bottom” 1344 areterms that refer to specific sides of the battery cell 1300, where thetop 1342 and bottom 1344 adjacent the front 1346 and rear sides 1348 ofthe battery cell 1300 is affixed to the flexible PCB 100, the outwardfacing surface 1332 may be on a front 1346 of the battery cell 1300 isopposite the bottom 1344 side and faces towards an interior surface of ahousing of the CWB. FIG. 13D shows a top view of the battery cell 1300that illustrates a thickness of the battery cell 1300. FIG. 13B shows anillustrative side view of the battery cell 1300. While lithium-ionbattery cells in a pouch-cell format are discussed, other batteryformats or chemistries may be used, such as prismatic battery cells,can-type battery cells, and the like.

In some cases, connection locations for each battery cell 1300 may bemarked on the flexible PCB 100 Additionally or alternatively, batterycell connection locations may include a rigidizing material, or may beotherwise reinforced such as via attachment of a battery cell module.Each battery cell connection location may be associated with a pair ofcutouts 140 for the anode and cathode connections, as discussed above.Here, a battery cell module 1300 may be physically attached to thesubstrate of the flexible PCB 100, such as by use of an adhesivematerial (e.g., glue, tape, etc.). Electrically conductive cathode andanode connection tabs 1302, 1304 may be inserted through a correspondingcutout 140 so that the connection tabs 540 may be welded, or otherwiseconnected to the connection pad 150 on the rear side of the flexible PCB100 to create an electrical connection between the battery cell 1300 andthe flexible PCB 100. The cathode and anode connection tabs 1302, 1304may be different materials. For instance, the electrically conductivecathode and anode connection tabs 1302, 1304 may comprise one or more ofaluminum, copper, nickel, or other materials.

FIGS. 14A-14E show illustrative views of a battery cell module 1400comprising a battery cell (e.g., the battery cell 1300) and a batterycell attenuating member 710 (e.g. an attenuating member made of aresilient, shock absorbing material) according to aspects of thisdisclosure. In the illustrative example, the battery cell attenuatingmember 710 may be affixed to a top surface (e.g., top 1320) of thebattery cell 1300 to form the battery cell module 1400. In some cases,the battery cell attenuating member 710 may be affixed with glue, epoxy,tape or other adhesive substance. In some cases, as can be shown betweenthe views of FIGS. 14C and 14D, the attenuating member may be alignedwith a center line of the battery cell 1300. For example, one or morecenter lines of the attenuating member 710 may be aligned with one ormore corresponding center lines of the battery cell 1300. In some cases,the attenuating member may be slightly offset or from a center line ofthe battery cell 1300. For example, a first edge of the attenuatingmember 1310 may be aligned with a corresponding edge of the battery cellpouch, while a second opposite edge of the battery cell attenuatingmember 710 may be aligned with the foil external to the opposite edge ofthe battery cell pouch.

FIGS. 15A and 15B show partial illustrative views of at least onebattery cell module 1400 attachments to the flexible PCBA 500 accordingto aspects of this disclosure. For example, battery cell tabs (thecathode tab 1302 and the anode tab 1304) are shown in FIG. 15A as beingpassed through the cut-out 140 and/or bent around an edge of theflexible PCB 100 and electrically and physically attached an associatedbonding pad 150. FIG. 15B shows an edge view of a physical arrangementfor a battery cell module 1400 attachment to the flexible PCB 100.

Because of the compact nature of the CWB and the folded PCBA 1000, theelectrical connection between the connection pads 150 and the batteryconnection tabs (e.g., tabs 1540A, tabs 1540B) may be minimized withrespect to the height of the overall connection relative to the inwardfacing surfaces 520A, 520B, as shown in FIGS. 15C and 15D. For instance,by using a welding technique that applies localized heat over a smalleramount of time compared to traditional soldering, the amount ofmaterial, and heat, needed to form a solid connection may be reduced.This means that the outward facing surface of the connection tab 1540may be have little to no additional material on it after being securedto the pad 150. Further, by minimizing applied heat during theconnection process, a probability that the folded PCBA 1000, the batterycell 1300, or other component near the connection site may be damaged issimilarly reduced. In some cases, the joint may be formed using only byjoining the material of the pad 150 and the material of the connectiontab 540 without the addition of solder, weld filler, or any additionalmaterial. By minimizing the amount of material in the joint, the height,H1 shown in FIG. 15E, of the connection may be controlled to reduce theoverall thickness of the folded PCBA 1000. As shown in FIG. 15E, theheight, H1, may be defined as the distance between an outward facingsurface 1536 of each connection tab 1540A, 1540B and the rear or inwardfacing surface 520A or 520B of the flexible PCB 100. In some cases, thejoint formed by joining the material of the pad 150 with the material ofthe connection tab 540 may be made via a process capable of minimizingthe height of the joint, such that the joint thickness is much less thanthe thickness of the connection tab 540. For example, the height, H1, ofthe joint may be made via a process (e.g., laser welding) such that atleast a portion of the connection tab 540 and/or a portion of the pad150 may be joined together with a joint height that is less than theheight of a joint of similar materials made through use of a differentprocess (e.g., soldering). For example, the height H1 may beapproximately 30% of the thickness of the connection tab 540 or may bewithin a range of 10% to 70% of the thickness of the connection tab 540.

In some regions of the PCBA 1000, such as for battery cell 1300B, eachconnection tab 540 may extend through a cutout 140 of the flexible PCB100 to attach to its corresponding connection pad 150, while in otherregions, connection tabs 540 may extend from respective battery cell1300 and wrap around an upper edge of the flexible PCB 100 beforeattaching to its corresponding connection pad 150. For example, as shownin FIGS. 15C and 15D, battery cell 1300A that may be positioned near anedge of the flexible PCB 100 (e.g., a battery cell may not have anadjacent battery cell positioned adjacent to it on the side of thebattery cell that has the connecting tabs) may have connection tabs1540A that extend away from the battery cell and wrap around an upperedge of the flexible PCB 100 before extending along an opposite side ofthe flexible PCB 100 before attaching to connection pad 150.

FIGS. 16 and 17 show different perspective views of a battery cellmatrix or grid associated with a flexible PCBA according to aspects ofthis disclosure. For example, the flexible PCBA assembly 1600 mayinclude a number of battery cells arranged in a matrix configuration1610, such as a 5×4 matrix, with one position having an opening for aconnector interface. In some cases, the flexible PCBA 1600 may include a3-dimensional matrix configuration 1620, such as a 5×4×2 matrixconfiguration, where some matrix positions may not include battery cellmodules, but may include circuitry modules, connection modules, openspaces and/or the like. FIG. 17 shows a view of an opposite side of theflexible PCBA 1600 of FIG. 16, where positions of the matrix may befilled battery cell modules, a connector module 1710, and/or one or morecircuitry modules 1720, 1730. Considering the view of FIG. 17, a3-dimensional (e.g., a 5×4×2) battery cell matrix configuration 1620 mayinclude the 5×4 matrix configuration 1610 of FIG. 16 and the 5×4 matrixconfiguration 1700 of FIG. 17. In some cases, adjacent columns of thebattery cell matrix configuration 1700 (e.g., column 1743, column 1745)may have a spacing between about 4.5 mm to about 5.5 mm (e.g., about 5mm) and adjacent rows of the battery cell matrix 1700 (e.g., row 1742,row 174) may have a spacing between about 6.5 mm to about 7.5 mm (e.g.,about 7 mm). The spacing between adjacent rows and/or adjacent columnsmay be determined, at least in part, based on a size and/or shape of abattery module to allow an assembled CWB to meet power, flexing, and/orsizing requirements set forth in a specification and/or standard, suchas to meet the requirements of MIL-PRF-32383/4A.

In some cases, a battery cell matrix may include only battery cells,such as a 3×3 battery cell matrix, a 4×4 battery cell matrix, a 5×4battery cell matrix, or other single-sided or double-sided matrixconfiguration within a flexible and sealed housing, where control andmonitoring circuitry may be externally connected (e.g., via a flexibleconnector, a cable, and/or the like) to the battery cell matrix, eitherwithin or external to a CWB housing. The specific matrix configurationsand spacings are given for illustrative purposes and other matrixconfigurations and spacings may be contemplated within the scope of thisdisclosure.

FIGS. 18A-18D show different side views of the flexible PCBA of FIGS. 16and 17 from a perspective of each of four different edges according toaspects of this disclosure. For example, FIG. 18A shows a 3×2 matrix ofbattery cell modules with a connector module, FIGS. 18B and 18C show 4×2and 5×2 matrices of battery cell modules, respectively, and FIG. 18Dshows a 2×2 matrix 1810 of battery cell modules, a 2×2 matrix 1820 ofbattery cell modules and circuitry modules, and a connector interface1830. FIGS. 19 and 20 show partial views of the illustrative PCBA 1600of opposite sides near the connector module 170.

As shown in FIGS. 21 and 22, the battery cell assembly 2100 may bereceived into a housing 2160 to provide at least physical and/orenvironmental protection for the CWB 2110. The housing 2160 may includean upper housing member 2162 and a lower housing member 2164. The upperhousing member 2162 and lower housing member 2164 may be connectedtogether to form an interior cavity 2166, as shown in FIG. 21. Inaddition, the upper housing member 2162 and lower housing member 2164may be sealed together along the perimeter to protect the battery cellassembly 2100 from to prevent ingress of solid material and/or liquidmaterial. Accordingly, the CWB 2110 may meet the requirements ofMIL-PRF-32383/4A. Each housing member 2162, 2164 may be formed from apolymeric material using a molding or other technique known to oneskilled in the art.

The arrangement of the battery cell modules 2130 on the outward facingsurfaces of the flexible PCBA 500 places the battery cell modules suchthat an outward facing surface of each battery cell module faces aninterior surface of either the upper housing member 2162 or the lowerhousing member 2164. Additionally, a plurality of battery cell shockabsorbing members may be individually attached to the outward facingsurface of each battery cell. Each battery cell attenuating member maybe positioned between the outward facing surface and one of the interiorsurfaces of the respective upper or lower housing members 2162, 2164.

As discussed above, each battery cell may be connected to the flexiblePCB 100 using a means to reduce the height profile, while alsomaximizing the density of the matrix of the battery cells. As shown inFIG. 23, the installation process 2300 for each battery cell module 2130to the flexible PCB 100 may include multiple steps. As noted in step2305, the battery cell module 2130 may be attached to a correspondingbattery connection location 230 on one of the outward facing surfaces ofthe flexible PCB 100. The battery cell module 2130 may be attached usingan adhesive (i.e. liquid adhesive, double-sided tape, or other similarmethod) that is positioned between the rear side of the battery cell ofthe battery cell module 2130 and the corresponding outward facingsurface. When a tape is used, the tape may have a surface area similarto the surface area of the rear side of the battery cell of the batterycell 2130.

In step 2310, the cathode tab of each battery cell may be routed eitherto wrap around an edge of the flexible PCB 100 (if the battery cellmodule 2130 is located along an edge of the flexible PCB 100) or througha cut-out 140 (if the battery cell module 2130 is located away from anedge of the flexible PCB 100). The cathode tab is then formed or bentsuch that the cathode tab extends substantially parallel to acorresponding inward facing surface of the flexible PCB 100 and onto theappropriate electrical connection pad 150. In step 2315, an electricalconnection may then be created between the cathode tab and theelectrical connection pad 150 or its corresponding surface coating. Theelectrical connection may be formed using a technique to create anelectrical connection between metal interfacing materials, such asultrasonic welding, laser welding, or other appropriate weldingtechnique. By using laser welding or ultrasonic welding, the differentmaterials such a cathode tab that includes aluminum to an ENIG surfacecoating without additional filler materials which can help minimize theheight, H1, of the tab to the rear surface of the flexible PCB 100(e.g., an inward facing surface) of the flexible PCB 100. In steps 2320and 2325, the steps of routing and connecting the cathode tab may berepeated for the anode tab of the battery cell module 2130 to completethe electrical connection for the battery cell 2130. In some examples,the anode tab may be routed and connected before the cathode tab. Asanother option, to accommodate a production environment, the attachmentsteps may be done as groupings such that all of the battery cell modules2130 may be affixed with adhesive first, then the tabs may be routedappropriately, and then the tabs may be have the electrical connectionsformed using the appropriate welding technique (e.g., each batteryconnection tab 540, such as the cathode tab and/or the anode tab, may bewelded individually in a sequence until all of the electricalconnections are formed).

A CWB assembly may include an array of a first quantity of battery cellsdisposed adjacent to one another in a horizontal direction and a secondquantity of battery cells disposed adjacent to one another in a verticaldirection. The array of battery cells may be arranged in a grid-likepattern. Each of the battery cells may be encased or housed in a batterycell housing separate from other battery cells. A battery cell asdescribed herein may include a plurality of individual battery cellelements that are electrically connected together to form a compoundbattery cell that electrically performs as a single unit. Each of thebattery cell housings may be physically connected to adjacent batterycell housings by flexible elements (e.g., a flexible printed circuitboard), thereby facilitating a surface outline or shape of the array ofbattery cells to generally conform to a surface outline or shape of auser wearing the CWB assembly. One or more of the battery cell housingsmay include a positive-charge electrical terminal and a negative-chargeelectrical terminal that are electrically connected with the batterycell within an interior of the battery cell housing and provideelectrical power to electrical devices disposed exterior to the batterycell housing. Electrical terminals of a plurality of the battery cellsin the array of battery cells may be connected together to routeelectrical current through the plurality of the battery cells and a setof positive-charge and negative-charge electrical terminals that areshared among the plurality of the battery cells. The positive-chargeelectrical terminal and the negative-charge electrical terminal mayprovide an electrical current that passes through an electricallyconductive path, for example, through an electronic device, via transferof electrons through the electrically conductive path between thepositive-charge electrical terminal and the negative-charge electricalterminal on the exterior of the battery cell housing. The CWB assemblymay include a set of positive-charge and negative-charge electricalterminals that are shared among the plurality of the battery cells ofthe array of battery cells. The plurality of the battery cells may beelectrically coupled together, for example, in series or in parallel.

While aspects of the disclosure have been described with reference tobattery cells and/or a CWB comprising battery cells, arrangements andmethods as described herein may also be applied to other devices andsystems having a flexible PCBA to maximize space within a housing. Forexample, the arrangements and methods described herein may apply to anyelectronic device disposed within a housing for which maximizing usableinterior space within a housing by folding a flexible PCBA within theavailable interior space is desired. Examples of such electronic devicesmay include underwater cameras, sonar devices, radar devices, lidardevices, emergency radio beacons, satellite communications devices,terrestrial wireless communications devices, global positioning system(GPS) receivers, electronic environmental sensor devices, electronicmedical devices, computing processors, solar cell based power generationdevices, wave motion based power generation devices, fuel cell basedpower generation devices, battery charging controllers, and/or portablechemical batteries for powering electronic or electrical devices.

In an illustrative example, a conformal wearable battery may include aplurality of battery cells and a flexible printed circuit board assembly(PCBA). The flexible PCBA may include a plurality of physical connectionsections disposed in a grid like pattern, wherein each of the pluralityof battery cells is physically affixed to the flexible PCBA at acorresponding physical connection section of the plurality of physicalconnection sections, a bend axis disposed between two parallel physicalconnection sections, wherein the bend axis facilitates folding of theflexible PCBA in half. Additionally, the flexible PCBA may include aplurality of first cut-outs disposed along the bend axis, wherein eachfirst cut-out of the plurality of first cut-outs is disposed parallel tothe bend axis and a plurality of second cut-outs disposed across thebend axis, wherein each second cut-out of the plurality of secondcut-outs are disposed perpendicular to the bend axis.

The conformal wearable battery of the illustrative example may include afirst plurality of electrical connections each connecting a cathode of acorresponding battery cell of the plurality of battery cells and secondplurality of electrical connections each connecting an anode of thecorresponding battery cell of the plurality of battery cells toelectrical conductors of the flexible printed circuit board assembly.

The conformal wearable battery may include a plurality of battery cells,at least one circuitry module configured to control and monitor chargingand discharging of the plurality of battery cells, and a flexibleprinted circuit board assembly (PCBA). The flexible PCBA may include aplurality of physical connection sections disposed in a grid likepattern, wherein each of the plurality of battery cells and the at leastone circuitry module is physically affixed to the flexible PCBA at acorresponding physical connection section of the plurality of physicalconnection sections.

The conformal wearable battery of the illustrative example may include aflexible PCBA that includes a first plurality of electrical connectionseach connecting a cathode of a corresponding battery cell of theplurality of battery cells and second plurality of electricalconnections each connecting an anode of the corresponding battery cellof the plurality of battery cells to electrical conductors of theflexible printed circuit board assembly.

The conformal wearable battery of the illustrative example may include aplurality of battery cells and at least one circuitry module that, whenaffixed to the flexible PCBA, forms a matrix of physical components. Thematrix of physical components may be a matrix of at least two rows andat least two columns.

The conformal wearable battery of the illustrative example may furtherinclude at least one connector configured to provide an electrical powerconnection from internal circuitry of the conformal wearable battery toan external device to be powered.

The conformal wearable battery of the illustrative example may includethe plurality of battery cells, where the at least one connector, andthe at least one circuitry module, when affixed to the flexible PCBA,comprises a matrix of physical components.

The conformal wearable battery of the illustrative example may comprisea bend axis that is a center of the grid like pattern of the physicalconnection sections when the flexible PCBA is unfolded. The conformalwearable battery of the illustrative example may include a flexible PCBAhaving each of the plurality of battery cells physically attached to afirst side of the flexible PCBA. The conformal wearable battery of theillustrative example may include the flexible PCBA having each of theplurality of battery cells physically attached to a first side of theflexible PCBA and each of the plurality of battery cells electricallyconnected to the flexible PCBA on a second side of the flexible PCBAthat is opposite the first side. The conformal wearable battery of theillustrative example may include the flexible PCBA having the pluralityof battery cells disposed on an outside surface of the flexible PCBA,when the flexible PCBA is in a folded configuration.

The conformal wearable battery of the illustrative example may include aplurality of battery cells that are arranged in a three-dimensional gridpattern. The conformal wearable battery of the illustrative example mayinclude a sealed flexible housing wherein the flexible PCBA is disposedwithin an interior cavity of the sealed flexible housing and wherein theflexible PCBA is in a folded configuration.

An illustrative system may include a plurality of battery cell modulesand a flexible printed circuit board assembly (PCBA). The flexible PCBAmay further include a plurality of battery cell connection sectionsdisposed in a grid-like pattern along a first surface of the flexiblePCBA where each of the plurality of battery cell modules is electricallyattached to the flexible PCBA on a second surface of the flexible PCBAin a grid-like pattern, wherein the second surface is opposite the firstsurface.

The illustrative system may further include a housing, wherein theflexible PCBA, when in a folded configuration, is located within thehousing.

The illustrative system may include a plurality of battery cell modules,where each of the plurality of battery cell modules includes a batterycell and an attenuating member made of a resilient material. Eachbattery cell may be a lithium-ion battery cell. The illustrative systemmay include a plurality of battery cells arranged in a three-dimensionalgrid pattern when the flexible PCBA is in a folded configuration.

An illustrative flexible printed circuit board assembly (PCBA) mayinclude a plurality of battery modules physically affixed to theflexible PCBA, where the plurality of battery modules is arranged in agrid-like pattern and a bend axis near an approximate mid-point of theflexible PCBA. When the flexible PCBA is bent along the bend axis, theflexible PCBA is in a folded configuration and, when the flexible PCBAis in a folded configuration, the plurality of battery modules isdisposed in a three-dimensional grid-like pattern.

The illustrative flexible PCBA may include a plurality of flexiblesections, wherein the flexible sections allow for the flexible PCBA toflex between adjacent rows and adjacent columns of battery modules. Theillustrative flexible PCBA may include at least one circuitry modulethat comprises a portion of the grid-like pattern.

A conformal wearable battery may include a plurality of battery cellsand a flexible printed circuit board (PCB). In some cases, each batterycell may include a pair of electrically conductive elements thatcorrespond to either a cathode or an anode of each battery cell. Theflexible PCB may include a plurality of physical connection sectionsdisposed in a grid-like pattern on a first side of the flexible PCB,were each of the plurality of battery cells may be disposed associatedwith a corresponding physical connection section of the plurality ofphysical connection sections. The flexible PCB may include a pluralityof electrical connection pads linearly disposed on a second sideopposite the first side of the flexible PCB, where the plurality ofelectrical connection pads may include an electrically conductivesurface coating. The electrically conductive surface coating maycomprise an electroless nickel immersion gold (ENIG) surface coatingand/or a lead-free immersion silver surface coating.

In some cases, the pair of electrically conductive elements may extendsubstantially parallel to and along the second side of the flexible PCBand each of the electrically conductive elements may be connected to acorresponding electrical connection pad of the plurality of electricalconnection pads on the second side of the flexible PCB forming anelectrical connection.

In some cases, the conformal wearable battery may include a plurality ofbattery cells that may be configured as pouch cell packaged polymerlithium-ion batteries Each battery cell of the plurality of batterycells may be physically attached to the first side of the flexible PCB.

In some cases, the flexible PCB of the conformal wearable battery mayinclude a plurality of cutouts extending through the flexible PCB,wherein at least one cutout of the plurality of cutouts is locatedadjacent to an electrical connection pad of the plurality of electricalconnection pads. Each conductive element of the pair of electricallyconductive elements may extend through a corresponding cutout of theplurality of cutouts. In some cases, the electrical connection betweeneach electrically conductive element of the pair of electricallyconductive elements and the corresponding electrical connection pad ofthe plurality of electrical connection pads may be joined with a weld,such as by using one or more of a laser welding process and/or anultrasonic welding process.

In some cases, a connection pad of the plurality of electricalconnection pads may have a width that is within a range of 1.8 times and3 times a width of an electrically conductive element of the pair ofelectrically conductive elements and/or a height electrical connectionmay be within a range of 10% to 70% of a thickness of an electricallyconductive element of the pair of electrically conductive elements.

In some cases, a system may include a first plurality of battery cells,wherein a first battery cell of the first plurality of battery cellincludes a first pair of electrically conductive elements and a secondplurality of battery cell, wherein a second battery cell of the secondplurality of battery cell includes a second pair of electricallyconductive elements, and may also include a flexible printed circuitboard (PCB). The flexible PCB may include a plurality of battery cellconnection sections disposed in a grid-like pattern along a firstsurface of the flexible PCB, a plurality of cutouts disposed adjacentand parallel to an edge of the plurality of battery cell connectionsections, where the plurality of cutouts is arranged as multiple pairsof cutouts arranged adjacent a majority of the plurality of battery cellconnection sections. The flexible PCB may also include a plurality ofelectrical connection pads disposed on a second surface of the flexiblePCB opposite the first surface, where a majority of the plurality ofelectrical connection pads may be arranged adjacent the plurality ofcutouts and the plurality of electrical connection pads may include anelectrically conductive surface coating. In some cases, an electricallyconductive element of the first pair of electrically conductive elementsmay wrap around an edge of the flexible PCB and may extend along thesecond surface of the flexible PCB. The electrically conductive elementof the first pair of electrically conductive elements may connect to acorresponding electrical connection pad of the plurality of electricalconnection pads forming a first electrical connection and anelectrically conductive element of the second pair of electricallyconductive elements may extend through a cutout of the plurality ofcutouts such that each electrically conductive element of the secondpair of electrically conductive elements connects to a correspondingelectrical connection pad of the plurality electrical connection padsforming a second electrical connection.

In some cases, the system may further include the first electricalconnection between the electrically conductive element of the first pairof electrically conductive elements and the corresponding electricalconnection pad of the plurality of electrical connection pads may bejoined with a weld, such as by using a laser welding process and/orusing an ultrasonic welding process. In some cases, the connection padof the plurality of electrical connection pads may have a circular shapewith a diameter that is within a range of 1.8 times and 3 times a widthof an electrically conductive element of the pair of electricallyconductive elements.

In some cases, a flexible printed circuit board assembly (PCBA) mayinclude a flexible printed circuit board (PCB) that may include a firstside and a second side opposite the first side. The flexible PCBA mayfurther include a plurality of electrical connection pads disposed onthe second side of the flexible PCB, where the plurality of electricalconnection pads may be arranged in multiple pairs of electricalconnection pads and the plurality of electrical connection pads mayinclude an electrically conductive surface coating. In some cases, theflexible PCBA may include a plurality of cutouts linearly disposed inthe flexible PCB and adjacent to corresponding electrical connectionpads and a plurality of battery cell modules physically affixed to thefirst side of the flexible PCB, were the plurality of battery cellmodules may be arranged in a grid-like pattern and may include pouchcell packaged polymer lithium-ion material. In some cases, each batterycell module of the plurality of battery cell modules may include a pairof electrically conductive elements that extend substantially parallelto the second side of the flexible PCB and connect to correspondingelectrical connection pads of the plurality of electrical connectionpads forming an electrical connection for each battery cell module. Insome cases, the electrical connection between each electricallyconductive elements of the pair of electrically conductive elements andthe corresponding electrical connection pads of the plurality ofelectrical connection pads may be formed using a welding process. Insome cases, a connection pad of the plurality of electrical connectionpads may have a circular shape with a diameter that is within a range of1.8 times and 3 times a width of an electrically conductive element ofthe pair of electrically conductive elements. In some cases, eachelectrical connection pad of the plurality of electrical connection padsmay include an electroless nickel immersion gold (ENIG) surface coating.

Aspects of the disclosure have been described in terms of illustrativeexamples thereof. Numerous other examples, modifications, and variationswithin the scope and spirit of the appended claims will occur to personsof ordinary skill in the art from a review of this disclosure. Forexample, one or more of the steps depicted in the illustrative figuresmay be performed in other than the recited order, and one or moredepicted steps may be optional in accordance with aspects of thedisclosure.

What is claimed is:
 1. A conformal wearable battery comprising: aplurality of battery cells, each battery cell of the plurality ofbattery cells comprising: a lithium-ion pouch cell; and a plurality ofattenuating members, each attenuating member affixed to an exteriorsurface of the lithium-ion pouch cell; at least one circuitry moduleconfigured to control charging of the plurality of battery cells,wherein the plurality of battery cells comprises a first battery celland a second battery cell; and a flexible printed circuit board assembly(PCBA) comprising: a plurality of physical connection sections disposedin a grid like pattern, wherein each of the plurality of battery cellsand the at least one circuitry module is physically affixed to theflexible PCBA at a corresponding physical connection section of theplurality of physical connection sections; a plurality of flexibleregions distributed between the physical connection sections disposed inthe grid like pattern, wherein the plurality of flexible regions allowsthe conformal wearable battery to flex in response to an applied force;a plurality of electrical connection pad pairs, wherein each pad pair ofthe plurality of electrical connection pad pairs is positioned parallelto an edge of the flexible PCBA and is associated with a correspondingphysical connection section, wherein each pad pair of the plurality ofelectrical connection pad pairs is positioned adjacent and parallel to acorresponding flexible region, wherein the plurality of electricalconnection pad pairs comprises a first electrical connection pad pairand a second electrical connection pad pair and wherein the firstelectrical connection pad pair is linearly aligned with the secondelectrical connection pad pair; a pair of cutouts in the flexible PCBAthrough which a first pair of electrically conductive elements of thefirst battery cell extend, wherein the first pair of electricallyconductive elements of the first battery cell are electrically connectedto the first electrical connection pad pair; and an edge of the flexiblePCBA around which a second pair of electrically conductive elements ofthe second battery cell wraps, wherein the second pair of electricallyconductive elements of the second battery cell are electricallyconnected to adjacent pads of the second electrical connection pad pair.2. The conformal wearable battery of claim 1, wherein the flexible PCBAcomprises a first plurality of electrical connections each connecting acathode of a corresponding battery cell of the plurality of batterycells and second plurality of electrical connections each connecting ananode of the corresponding battery cell of the plurality of batterycells to electrical conductors of the flexible printed circuit boardassembly.
 3. The conformal wearable battery of claim 1, wherein theplurality of battery cells and the at least one circuitry module, whenaffixed to the flexible PCBA, comprises a matrix of physical components.4. The conformal wearable battery of claim 3, wherein the matrix ofphysical components comprises a matrix of at least two rows and at leasttwo columns.
 5. The conformal wearable battery of claim 1, wherein theconformal wearable battery comprises at least one connector configuredto provide an electrical power connection from internal circuitry of theconformal wearable battery to an external device to be powered.
 6. Theconformal wearable battery of claim 5, wherein the plurality of batterycells, the at least one connector, and the at least one circuitrymodule, when affixed to the flexible PCBA, comprises a matrix ofphysical components.
 7. The conformal wearable battery of claim 1,wherein a bend axis comprises a center of the grid like pattern of thephysical connection sections when the flexible PCBA is unfolded.
 8. Theconformal wearable battery of claim 1, wherein each of the plurality ofbattery cells is physically attached to a first side of the flexiblePCBA.
 9. The conformal wearable battery of claim 1, wherein each of theplurality of battery cells is physically attached to a first side of theflexible PCBA and each of the plurality of battery cells is electricallyconnected to the flexible PCBA on a second side of the flexible PCBA,the second side being opposite the first side.
 10. The conformalwearable battery of claim 1, wherein the plurality of battery cells isdisposed on an outside surface of the flexible PCBA, when the flexiblePCBA is in a folded configuration.
 11. The conformal wearable battery ofclaim 10, wherein the plurality of battery cells is arranged in athree-dimensional grid pattern.
 12. The conformal wearable battery ofclaim 1, further comprising a sealed flexible housing wherein theflexible PCBA is disposed within an interior cavity of the sealedflexible housing and wherein the flexible PCBA is in a foldedconfiguration.
 13. A system comprising: a plurality of battery cellmodules comprising a first battery cell module and a second battery cellmodule, wherein each battery cell module of the plurality of batterycell modules comprises: a lithium-ion pouch cell comprising a cathodetab and an anode tab; and an attenuating member affixed to an exteriorsurface of the lithium-ion pouch cell; and a flexible printed circuitboard assembly (PCBA) comprising: a plurality of battery cell connectionsections disposed in a grid-like pattern along a first surface of theflexible PCBA; and a plurality of electrical connection pad pairscomprising a first pad pair and a second pad pair, wherein each pad pairof the plurality of electrical connection pad pairs is associated with acorresponding battery cell connection section, is positioned parallel toan edge of the flexible PCBA, and is positioned parallel to acorresponding flexible region of the flexible PCBA, wherein each of theplurality of battery cell modules is electrically attached to theflexible PCBA on a second surface of the flexible PCBA in a grid-likepattern via a corresponding pad pair, wherein the second surface isopposite the first surface and wherein the first electrical connectionpad pair is linearly aligned with the second electrical connection padpair; wherein the flexible PCBA comprises a pair of cutouts throughwhich a first cathode tab and a first anode tab of the first batterycell module extend, wherein the first cathode tab and the first anodetab are electrically connected to the first pad pair; and wherein theflexible PCBA comprises an edge around which a second cathode tab and asecond anode tab of the second battery cell module wrap, wherein thesecond cathode tab and the second anode tab are electrically connectedto the second pad pair.
 14. The system of claim 13, further comprising ahousing, wherein the flexible PCBA, when in a folded configuration, islocated within the housing.
 15. The system of claim 13, wherein a centerline of the attenuating member of each of the plurality of battery cellmodules is offset from a center line of the lithium-ion pouch cell. 16.The system of claim 14, wherein a first portion of the second surface ofthe flexible PCBA faces a second portion of the second surface when theflexible PCBA is in the folded configuration.
 17. The system of claim13, wherein the plurality of battery cell modules is arranged in athree-dimensional grid pattern when the flexible PCBA is in a foldedconfiguration.
 18. A flexible printed circuit board assembly (PCBA)comprising: a plurality of battery modules physically affixed to theflexible PCBA, wherein the plurality of battery modules is arranged in agrid-like pattern, wherein a first battery module is physically affixedto the flexible PCBA adjacent to a second battery module and whereineach battery module of the plurality of battery modules comprises: alithium-ion pouch cell; and an attenuating member affixed to an exteriorsurface of the lithium-ion pouch cell; a bend axis near an approximatemid-point of the flexible PCBA, wherein bending the flexible PCBA alongthe bend axis results in a folded configuration of the flexible PCBA;wherein, when the flexible PCBA is in the folded configuration, theplurality of battery modules is disposed in a flexible three-dimensionalgrid-like pattern on an exterior surface of the folded flexible PCBA,wherein the plurality of battery modules is electrically connected tothe flexible PCBA via a plurality of electrical connection pads disposedparallel and adjacent to a flexible section between adjacent rows ofbattery modules of the grid-like pattern, wherein the electricalconnection pads are on an interior surface of the folded flexible PCBA,and wherein each pad pair of the plurality of electrical connection padsis positioned parallel to an edge of the flexible PCBA and is associatedwith a corresponding physical connection section; and wherein firstelectrical connection tabs of the first battery module extend through apair of cutouts in the flexible PCBA and wherein the first electricalconnection tabs are electrically connected to a first pair of electricalconnection pads of the plurality of electrical connection pads; andwherein second electrical connection tabs of the second battery modulewrap around an edge of the flexible PCBA and wherein the secondelectrical connection tabs are electrically connected to a second pairof electrical connection pads of the plurality of electrical connectionpads.
 19. The flexible PCBA of claim 18, further comprising a pluralityof flexible sections, wherein the plurality of the flexible sectionsallows the flexible PCBA to flex between adjacent rows and adjacentcolumns of battery modules.
 20. The flexible PCBA of claim 18,comprising at least one circuitry module that comprises a portion of thegrid-like pattern.